Prosthetic attachment system and corresponding lock assembly

ABSTRACT

A prosthetic attachment system and corresponding lock assembly for connecting a distal end of a prosthetic liner to a distal end of a prosthetic socket. The lock assembly includes a base arranged to be supported by the distal end of the prosthetic socket, and defining a bore. An attachment pin is arranged to be carried by the prosthetic liner and insertable through the bore. A lock mechanism is arranged to be carried by the base and is rotatable about a rotation axis. The lock mechanism includes a control knob extending outwardly from a side of the base. The attachment pin is arranged to interact with the lock mechanism cause the control knob to spin at least one projection of the control knob about the rotation axis.

TECHNICAL FIELD

This disclosure is directed to a prosthetic attachment system, and inparticular to a lock assembly for locking a prosthetic liner to aprosthetic socket.

BACKGROUND

A typical prosthetic leg and foot include a socket, pylon, and foot. Asocket is the portion of a prosthesis that fits around and envelops aresidual limb or stump, and to which prosthetic components, such as afoot, are attached. The socket must fit closely to the residual limb toprovide a firm connection and support, but must also be sufficientlyloose to allow for circulation. Combined with proper fitting, the sockettransfers loads from the residual limb to the ground in a comfortablemanner.

A prosthetic liner is arranged as an interface between the socket andthe residual limb to increase comfort. Generally, the prosthetic linerincludes an elastomeric body having a closed distal end and an openproximal end pulled or rolled over the residual limb. The prostheticliner adheres to the residual limb surface and acts as an interfacebetween the residual limb and the socket by extending between andfacilitating contact between the residual limb and the rigid componentsof the socket.

Different mechanisms exist for holding the socket on the residual limbduring use of the prosthesis. For instance, locking pin-type systemsprovide an attachment pin at the closed distal end of the prostheticliner that engages a prosthetic-system lock assembly at the distal endof the socket. The lock assembly is connected to the components, such asthe pylon, connecting to the foot and effectively couples the liner, thesocket, and the components together. An unlocking mechanism can releasethe attachment of the prosthetic liner to the socket.

A problem inherent in conventional locking pin-type systems is that theyincorrectly lock if a user does not properly insert the attachment pinin the lock assembly. This problem can cause the failure of the lockassembly during use and significant injury to the user. Too much freeplay between the attachment pin and the lock assembly can cause a slackconnection, so that the residual limb undesirably moves up and downwithin the socket when the user is walking, an undesirable phenomenonknown as “pistoning.” The free play may also lead to premature wear ofthe attachment pin and lock components which can cause a failure of thelock.

Conventional lock assemblies are also known to make donning and doffingof the residual limb in the socket problematic. This problem isespecially evident for elderly users and others who commonly havedifficulty properly locating the attachment pin in the lock assembly dueto limited cognition, limited dexterity, or poor eyesight

There is a need for a prosthetic attachment system that makes donningand doffing of prosthetic socket easier and more intuitive, and whichminimizes pistoning and incorrect locking of the system.

SUMMARY

The disclosure describes various embodiments of a prosthetic attachmentsystem, particularly including a lock assembly for a prosthetic system,providing construction and design that facilitates a more intuitive andsecure connection between a residual limb and a prosthetic socket.

A lock assembly embodiment according to the disclosure is arranged forconnecting a distal end of a prosthetic liner to a distal end of aprosthetic socket. The lock assembly includes a base arranged to besupported by or at the distal end of the prosthetic socket, and definesa pin bore. An attachment pin is arranged to be carried by theprosthetic liner proximate the distal end and insertable through the pinbore. A lock mechanism is arranged to be carried by the base androtatable about a rotation axis. The lock mechanism includes a controlknob extending outwardly from a side of the base and has at least oneelongate projection extending in a direction transverse relative to therotation axis. The attachment pin is arranged to interact with the lockmechanism as the attachment pin moves distally through the pin bore, andcauses the control knob to spin the at least one projection about therotation axis.

The lock assembly may be provided as a kit for being added, for exampleretroactively or for retrofitting, to a socket and liner, or the socketand liner may be provided with a lock assembly according to thedisclosure. More broadly, a prosthetic attachment system comprises thesocket, liner, and the lock assembly, enabling improved and moreintuitive attachment when the socket and liner have such correspondingand interacting components.

When a user correctly pushes the attachment pin into the pin bore, theuser can see and/or feel the at least one elongate projection of thecontrol knob spinning. This advantageously provides a clear indicator orfeedback to the user that the attachment pin is correctly pushed intothe pin bore of the base. This is beneficial when donning or doffing thesocket for users with limited cognition, limited dexterity, and/or pooreyesight.

The at least one elongate projection of the control knob stops spinningonce the attachment pin is fully inserted or inserted to a predeterminedextent in the pin bore of the base. This observable change in the actionof the control knob has the effect of providing another clear indicatorthat the attachment pin is securely and fully inserted in the lockmechanism, which, in turn, reduces the likelihood of a user onlypartially inserting the attachment pin in the prosthetic lock assembly.This is advantageous because incomplete or partial insertion of theattachment pin in the pin bore could result in failure of the lockbetween the attachment pin and the lock mechanism and/or significantinjury to the user.

To verify that the attachment pin is fully engaged with the lockmechanism, the user can grasp the at least one elongate projection toturn the control knob in the same direction as it was spinning duringinsertion of the attachment pin in the pin bore. If the user is unableto turn the control knob, the attachment pin is fully engaged with thelock mechanism. If the user can turn the control knob, the rotation ofthe control knob is configured and arranged to draw the attachment pinfurther into the pin bore until it is fully engaged.

The combination of the control knob and the lock mechanism can thus makedonning and doffing of the socket easier and minimize incorrectattachment of the prosthetic socket system components by a user.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the presentdisclosure will become better understood regarding the followingdescription, appended claims, and accompanying drawings.

FIG. 1 is a partial side perspective view of a prosthetic attachmentsystem having a lock assembly according to the disclosure.

FIG. 2 is a perspective view of the lock assembly in FIG. 1.

FIG. 3A is a front perspective view of the control knob in FIG. 1.

FIG. 3B is a rear perspective view of the control knob in FIG. 1.

FIG. 4 is a perspective view of a control knob according to anotherembodiment of a prosthetic attachment system.

FIG. 5 is a front perspective view of a control knob according toanother embodiment of a prosthetic attachment system.

FIG. 6 is an exploded view of the lock assembly in FIG. 1.

FIG. 7 is a cross-sectional view of the lock assembly of FIG. 1 in theprosthetic attachment system.

FIG. 8 is a top perspective view of the base in FIG. 1 according to anembodiment.

FIG. 9 is a bottom view of an umbrella according to an embodiment of aprosthetic attachment system.

FIG. 10 is a perspective view of another embodiment of a lock assembly.

FIG. 11 is a top plan view of the lock assembly of FIG. 10.

The drawing figures are not necessarily drawn to scale, but instead aredrawn to provide a better understanding of the components, and are notintended to be limiting in scope, but to provide exemplaryillustrations. The figures illustrate exemplary configurations ofprosthetic attachment systems including lock assemblies, and in no waylimit the structures or configurations of a prosthetic attachment systemand components thereof including prosthetic attachment systems andcorresponding lock assemblies according to the present disclosure.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

A better understanding of different embodiments of the disclosure may behad from the following description read with the accompanying drawingsin which like reference characters refer to like elements.

While the disclosure is susceptible to various modifications andalternative constructions, certain illustrative embodiments are in thedrawings and are described below. It should be understood, however,there is no intention to limit the disclosure to the specificembodiments disclosed, but on the contrary, the intention covers allmodifications, alternative constructions, combinations, and equivalentsfalling within the spirit and scope of the disclosure.

It will be understood that unless a term is expressly defined in thisapplication to possess a described meaning, there is no intent to limitthe meaning of such term, either expressly or indirectly, beyond itsplain or ordinary meaning.

Embodiments of the present disclosure advantageously provide aprosthetic attachment system and corresponding lock assembly thatfacilitates a more intuitive and secure connection between a residuallimb and a prosthetic socket. FIG. 1 illustrates a prosthetic socketsystem 100 according to an embodiment including a socket 102, aprosthetic liner 104, and a lock assembly 106. The lock assembly 106 maybe provided as a kit of components provided interchangeably together, oras individual components forming part of the socket 102 or theprosthetic liner 104.

In the illustrated embodiment, the socket 102 comprises an adjustablesocket including a base 108 and a plurality of longitudinal supports 110connected to the base 108 and distributed about a longitudinal axis 112of the socket 102. The socket 102 can include a plurality of shellcomponents connected to the longitudinal supports 110 that collectivelyform a socket wall defining a receiving volume adapted to receive aresidual limb and a prosthetic liner worn thereon. The base 108 isconfigured to provide support for a distal end of the residual limb andcan comprise at least part of the lock assembly 106 for fixing orsecuring the residual limb or the prosthetic liner 104 to the socket102. The base 108 defines a pin bore 120 generally centrally disposedrelative to and within the base 108.

The socket 102 is radially adjustable between an open configuration anda closed configuration. In the open configuration, at least some of thelongitudinal supports 110 and/or shell components may move or are forcedradially outward relative to the longitudinal axis 112, increasing thereceiving volume and/or increasing the circumference of the socket 102.This effectively loosens the fit of the socket 102 on a residual limbinserted in the receiving volume and/or decreases the loading on theresidual limb from the socket wall or the longitudinal supports 110. Inthe closed configuration, at least some of the longitudinal supports 110and/or shell components are moved or forced radially inward relative tothe open configuration, decreasing the receiving volume or decreasingthe circumference of the socket 102. This may be particularlyadvantageous for donning and doffing, as the open configurationfacilitates easier insertion and removal of the limb residuum and theprosthetic liner 104.

A tensioning system can be arranged to selectively secure a residuallimb within the receiving volume by moving the socket 102 between theopen/expanded and closed configurations. Other examples and additionaldetails of suitable prosthetic sockets are included in U.S. Pat. No.8,795,385, granted Aug. 5, 2014, U.S. Pat. No. 9,248,033, granted Feb.2, 2016, U.S. Pat. No. 9,050,202, granted Jun. 9, 2015, U.S. Pat. No.9,962,273, granted May 8, 2018, U.S. Patent Application Publication2015/0230945, published Aug. 20, 2015, and U.S. Patent ApplicationPublication 2018/0221178, published Aug. 9, 2018, each of which isincorporated by reference in its entirety. While the socket 102 isdescribed as an adjustable socket, in other embodiments, the socket 102can comprise a conventional static socket devoid of adjustability. Theforegoing references are merely exemplary, and the socket 102 may haveany suitable construction, operation, or configuration.

An exemplary prosthetic liner can be found in U.S. Pat. No. 4,923,474,granted May 8, 1990, U.S. Pat. No. 6,136,039, granted Oct. 24, 2000, andU.S. Pat. No. 6,485,776, granted Nov. 26, 2002, each of which isincorporated by reference in its entirety. The foregoing references aremerely exemplary, and the liner 104 may have any suitable construction,composition, or configuration.

The prosthetic liner 104 is configured to be donned on the residual limband positioned in the socket 102. Typical liners are made of soft,stretchable material and protect the residual limb and act as aninterface between the socket 102 and the skin of the residual limb. Theprosthetic liner 104 generally includes a liner body having a proximalend, which is open, and a distal end, which is closed. The liner bodydefines an inner surface that interfaces with the skin, and an outersurface opposing the inner surface. The liner body can be formed of apolymeric or elastomeric material like silicone, copolymer gel,polyurethane, combinations thereof, or any other suitable material.

The distal end of the prosthetic liner 104 may include an umbrella 114that enables interconnection between the prosthetic liner 104 and thesocket 102. The umbrella 114 generally comprises an umbrella-shaped baseand a neck that depends from the center of the base. An internallythreaded center bore is formed in the neck.

An attachment pin 116 is secured to the distal end of the prostheticliner 104. The attachment pin 116 may be mounted to the prosthetic liner104 by being molded or threaded onto the distal end of the prostheticliner 104. In the illustrated embodiment, the attachment pin 116 can bethreaded into the internally threaded center bore of the umbrella 114.The attachment pin 116 is positioned to extend through the pin bore 120of the base 108 and thus through the distal end of the socket 102. Theattachment pin 116 includes a plurality of notches 118 formed along alongitudinal length thereof. The notches 118 are preferably axiallyspaced and define a curved configuration in axial cross-section. Theattachment pin 116 can include an upper shank portion arranged forattachment to the prosthetic liner 104.

A lock mechanism 122 (shown in FIG. 6) of the lock assembly 106 ispositioned in the base 108 to engage and secure the attachment pin 116within the base 108. The lock mechanism 122 is configured and arrangedto engage the attachment pin 116 with the lock mechanism 122 interactingwith the notches 118 of the attachment pin 116. It will be appreciatedthat the lock mechanism 122 can comprise any suitable lock mechanism.Other exemplary lock mechanisms are described in U.S. Pat. No.7,217,060, granted May 15, 2007, owned by the assignee of thisdisclosure and incorporated herein in its entirety by reference.

The lock assembly 106 includes a control knob 124 operably coupled tothe lock mechanism 122. According to the present disclosure, the controlknob 124 is arranged and configured to make donning and doffing of aprosthetic socket 102 easier, and to minimize incorrect locking of theattachment pin 116 in the lock mechanism 122. For instance, the controlknob 124 can comprise a button protruding a distance outwardly from aside of base 108, and having an oversized configuration such as defininga pair of projections 126, 128, each being elongate in form.

The lock mechanism 122 and the notches 118 of the attachment pin 116 canoperate to spin or rotate the control knob 124 about a rotation axis131. For instance, as the attachment pin 116 is being inserted throughthe pin bore 120 in the base 108, the interaction between the lockmechanism 122 and the notches 118 of the attachment pin 116 spins thecontrol knob 124 about the rotation axis 131.

When a user is correctly pushing the attachment pin 116 distally ordownwardly into the pin bore 120 of the base 108, the user can seeand/or feel the projections 126, 128 of the control knob 124 spinning.This advantageously provides a clear indicator or feedback to a userthat the attachment pin 116 is being correctly inserted into the pinbore 120 of the base 108. This is beneficial for users with limitedcognition, limited dexterity, and/or poor eyesight while donning thesocket 102.

The projections 126, 128 of the control knob 124 may stop spinning whenthe attachment pin 116 is fully inserted or inserted to a predeterminedextent in the pin bore 120 of the base 108. This observable change inthe action of the control knob 124 provides another indicator that theattachment pin 116 is securely and fully inserted in the lock mechanism122, which prevents a user from only partially inserting the attachmentpin 116 in the lock assembly 106. This is advantageous becauseincomplete or partial insertion of the attachment pin 116 could causefailure of the lock between the attachment pin 116 and the lockmechanism 122, accelerated wear of the components, and/or significantinjury to the user.

To verify that the attachment pin 116 is engaged with the lock assembly106, the user can grasp the projections 126, 128 to turn the controlknob 124 in the same direction as it was spinning during insertion ofthe attachment pin 116 in the pin bore 120. If the user cannot turn thecontrol knob 124, the attachment pin 116 is fully engaged with the lockmechanism 122. If the user can turn the control knob 124, the rotationof the control knob 124 is configured and arranged to draw theattachment pin 116 into the lock assembly 106 until it is fully engaged.

When it is desired to remove the attachment pin 116 from the base 108,the control knob 124 is configured so a user can push the control knob124 inwardly to disengage the lock mechanism 122 from the attachment pin116. The attachment pin 116 may be freely withdrawn from the base 108upon disengagement of the lock mechanism 122 from the attachment pin116. The combination of the control knob 124 and the lock mechanism 122thus makes donning and doffing of the socket 102 easier and minimizesincorrect locking of the prosthetic socket system 100 by a user.

FIGS. 3A and 3B illustrate the control knob 124 in additional detailaccording to an embodiment. The control knob 124 can have a bodydefining an inner surface 140 arranged to engage and/or face the base108, an outer surface 142 opposite the inner surface 140, and sidesurfaces 144 extending between the inner and outer surfaces 140, 142.The periphery of the outer surface 142 can define rounded or curvededges, improving the feel and ergonomics of the control knob 124. Thebody of the control knob 124 can be formed of plastic, rubber, foam,carbon fiber, metal, combinations thereof, or any other material whichwould provide enough strength to resist undesirable deformation duringuse. In an embodiment, the body can have a rigid configuration with anovermold having a flexible configuration applied thereto for enhancedgrip and comfort, and without compromising on or sacrificing overallstructural strength.

The projections 126, 128 extend in opposite directions along alongitudinal length of the body from a central portion 130 of the body.The projections 126, 128 may define an elongate configuration of thecontrol knob 124. The control knob 124 is shown having a generallytrapezoidal shape but can have any suitable shape. The projections 126,128 provide enhanced visual and/or tactile indicators to a user aboutthe engagement of the attachment pin 116 with the lock mechanism 122. Inaddition, the orientation and arrangement of the projections 126, 128provide a large ergonomic gripping area for the user, making operationof the control knob 124 easier for users with limited dexterity.

For instance, the side surfaces 144 of the projections 126, 128 canprovide additional gripping area for a user's thumb and fingers whenturning the control knob 124. The projections 126, 128 are shown havingthe same shape and being generally symmetrically arranged but in otherembodiments the projections 126, 128 can have different shapes and/ormay be arranged in asymmetric configurations. For instance, oneprojection can have a round shape and the other projection can have arectangular shape, helping to accentuate the spinning of the projections126, 128 for a user.

The outer surface 142 can include at least one textured region 132configured to improve grip and/or provide tactile feedback for a user,making it easier for a user with poor eyesight to locate the controlknob 124 on the base 108. The textured region 132 can comprise differentpatterns of protrusions and/or recesses formed along the outer surface142. For example, the textured region 132 can comprise a plurality ofrecesses distributed on the central portion 130, each defining alongitudinal length generally aligned with the longitudinal length ofthe control knob 124 so a user can observe or touch along thelongitudinal lengths of the recesses to help determine the orientationof the control knob 124. The depicted embodiment is merely exemplary,and the textured region 132 and protrusions or recesses may have anysuitable configuration.

The inner surface 140 of the control knob 124 can be contoured togenerally correspond to a contour of the side of the base 108. This canallow the control knob 124 to form a lower profile fit between thecontrol knob 124 and the base 108. The inner surface 140 can alsoprovide a support area for the control knob 124 against the base 108 ifthe control knob 124 engages with the base 108 when the control knob 124is pushed in.

As seen in FIG. 3B, a cylindrical portion defining a bore 136 is on theinner surface 140 of the control knob 124 and is configured and arrangedto facilitate a connection between the control knob 124 and the lockmechanism 122. The control knob 124 can rotate about a rotation axis 131defined at this connection. In an embodiment, the bore 136 can includeinternal threads along a length thereof configured to form a threadedconnection between the control knob 124 and the lock mechanism 122.Optionally, the body can include a gap 146 surrounding the cylindricalportion. This gap 146 can reduce the weight of the control knob 124.

According to a variation, the control knob 124 can be provided with aunique indicator (e.g., a double click, light, or vibration) when theattachment pin 116 is fully engaged with the lock mechanism 122, helpinga user determine when the socket 102 is safely secured to the residuallimb. This advantageously improves ease of use and helps reduce injuryto the user. In other embodiments, the control knob 124 can include acounting unit configured to count and display to the user how manyrevolutions the control knob 124 has completed after the attachment pin116 in inserted into the pin bore 120. In embodiments, the control knob124 may be configured with a power supply, a sensor, a processor, and atransmitter to communicate with a mobile device and to indicate that theattachment pin 116 is fully engaged, mitigating a need to physicallywatch the control knob 124 spin or rotate.

FIG. 4 illustrates a control knob 224 according to another embodiment.As in the previous embodiment, the control knob 224 is arranged andconfigured to makes donning and doffing of the socket 102 easier, and tominimize incorrect locking of the attachment pin 116 in the lockmechanism 122. The control knob 224 includes a body having an irregularshape defining an oversized head portion 230 including a rotation axis231 and a single projection 226 extending from the head portion 230 in adirection traversing the rotation axis 231. The rotation axis 231 can bedefined by a connection between the control knob 224 and the lockmechanism 122.

The projection 226 can have a width that tapers in a direction away fromthe head portion 230 and is arranged and configured so a user can seeand/or feel the projection 226 spinning when the user is correctlypushing the attachment pin 116 into the base 108, reducing the risk ofthe user incorrectly donning the socket 102. In addition, theorientation and arrangement of the projection 226 provides a largeergonomic gripping area for the user, making manual operation of thecontrol knob 224 easier for users with limited dexterity, such as byincreasing a user's leverage when manipulating the control knob 224.

FIG. 5 illustrates yet another embodiment of a control knob 324 arrangedand configured to make donning and doffing of the socket 102 easier andsafer. The control knob 324 can be configured similar to the foregoingembodiments, and may include a body having an elongate configuration anda rotation axis 331. A longitudinal length of the body extends in adirection traversing the rotation axis 331. The rotation axis 331 can bedefined by a drive shaft of the lock mechanism or a connection betweenthe control knob 324 and the lock mechanism 122. The control knob 324can include a first part 326 comprising a first projection and a secondpart 328 comprising a second projection extending in opposite directionstraversing the rotation axis 331.

Each part 326, 328 can have a different colored region. Thisadvantageously can help accentuate the spinning of the projections orparts for a user. For instance, the first part 326 can be colored yellowY and the second part 328 can be colored blue B so a user can moreeasily see that the parts 326, 328 or body is spinning when the user iscorrectly pushing the attachment pin 116 into the base 108 due to thealternating positions of the blue B and yellow Y regions. The depictedembodiment is merely exemplary, and any suitable configuration ofcolors, shapes, materials, or components may be utilized.

FIGS. 6 and 7 illustrate the lock mechanism 122 in greater detailaccording to an embodiment. The lock mechanism 122 is located inside ofthe base 108 of the socket 102 and comprises a shaft 150 for engagingthe attachment pin 116, a sleeve assembly 152 encompassing at least aportion of the shaft 150, a bearing-and-groove arrangement 154 providingcooperative movement between the sleeve assembly 152 and the shaft 150,and a clutch device 160 arranged to securely receive the sleeve assembly152 and permit smooth and/or generally uniform rotation of the shaft 150and the sleeve assembly 152, and consequently the control knob 124.

The shaft 150, the sleeve assembly 152, and the clutch device 160generally extend along a common axis L, which may be the axis ofrotation 131 or may be a different axis. By extending commonly along theaxis of rotation 131, the shaft 150, the sleeve assembly 152, the clutch160, and the control knob 124 can rotate uniformly to provide indicia toa user that the attachment pin 116 is being properly inserted into thepin bore 120 for effective and intuitive attachment of the components ofthe prosthetic attachment system 100.

The shaft 150 includes an engaging member 156, located at a first end,such as a pinion, a threaded portion 159 located at a second endthereof, and a central portion interposed between the pinion 156 and thethreaded portion 159. The pinion 156 is configured and arranged tooperably communicate with the pin bore 120 and to engage the attachmentpin 116 so teeth of the pinion 156 can mesh or engage with the notches118 of the attachment pin 116. The pinion 156 may be formed integrallywith the shaft 150, or the pinion 156 may be attached to the shaft 150.The teeth of the pinion 156 may correspond in size and configuration tothe configuration of the notches 118 of the attachment pin 116.

The shaft 150 defines at least one groove 154 longitudinally extendingalong the central portion of the shaft 150. The at least one groove 154preferably has a depth with contours sufficient to accommodate at leasta portion of at least one ball bearing 158. The sleeve assembly 152defines along its interior surface at least one groove located at ornear a first end portion intended to be near or adjacent to the pinion156. The sleeve assembly 152 is positioned on the shaft 150 so thegrooves of the sleeve assembly 152 are aligned with the at least onegroove 154 of the shaft 150, with a groove 154 of the shaft 150 and acorresponding groove of the sleeve assembly 152 defining a pair ofmutually opposed grooves.

The at least one ball bearing 158 is seated in one of the pairs ofmutually opposed and corresponding grooves of the shaft 150 and thesleeve assembly 152, respectively. Preferably a plurality of ballbearings 158 are provided, with at least one ball bearing 158corresponding to each of the pairs of mutually opposed grooves. The atleast one ball bearing 158 is configured to permit movement ortranslation of the shaft 150 along the longitudinal axis L relative tothe sleeve assembly 152, and may be configured to prohibit rotation ofthe shaft 150 relative to the sleeve assembly 152. It will be understoodthat different bearing elements, such as cylinders, may be provided inplace of ball bearings in the passageways formed by the grooves.

Preferably, the grooves are configured to permit the shaft 150 to movewithin the sleeve assembly 152 a distance until the pinion 156completely disengages from the notches 118 of the attachment pin 116,permitting the attachment pin 116 to be freely removed from the lockmechanism 122 without impediment.

The sleeve assembly 152 is securely received for rotation in onedirection within the one-way clutch device 160. For instance, the sleeveassembly 152 can be secured within a first bore portion of the clutchdevice 160 by rollers (not shown) arranged about the inner periphery ofthe clutch device 160. When the sleeve assembly 152 is rotated in afirst direction, the rollers are configured within the first boreportion to wedge against or contact the outer periphery of the sleeveassembly 152 to prevent further rotation of the sleeve assembly 152.

As taught in U.S. Pat. No. 7,217,060, the rollers may be those found ina conventional unidirectional or one-directional roller clutch such as aroller clutch produced by Stock Drive Products of New Hyde Park, N.Y.under catalog number 599NH3MURCO406.

When the sleeve assembly 152 is rotated in a second or oppositedirection, the rollers freely rotate against the sleeve assembly 152. Itwill be understood that the permitted rotational direction of the sleeveassembly 152 within the clutch device 160 corresponds to the rotationaldirection in which the pinion 156 of the shaft 150 drives the attachmentpin 116 into the base 108. The clutch device 160 may include a pluralityof external threads arranged for engaging a plurality of internalthreads of a transverse bore 168 defined by and within a thickness ofthe base 108.

The threads of the clutch device 160 and the transverse bore 168 mayadvantageously facilitate rotation of the lock mechanism 122 about therotation axis 131 while preventing disengagement of the lock mechanism122 from the base 108. As depicted in FIG. 7, the transverse bore 168may extend generally obliquely relative to the bore 120 so as tofacilitate optimal contact between the attachment pin 116 and the lockmechanism 122, with the lock mechanism 122 operably communicating withthe bore 120 and the attachment pin 116.

A coupler 162 includes a first end arranged to couple with the driveshaft 150, and second end arranged to couple with the control knob 124,and a radially extending flange 164 defined between the first and secondends. It will be appreciated that the coupler 162 can be coupled to thedrive shaft 150 and the control knob 124 in any suitable manner. Aresilient member 166 such as a spring is configured to engage betweenthe flange 164 and a seat flange of the clutch device 160.

The control knob 124 can be connected to the second end of the coupler162. The lock mechanism 122 is configured so that depression of thecontrol knob 124 inwardly or towards the base 108 urges travel of thedrive shaft 150 along the longitudinal axis L, and rotation of eitherthe drive shaft 150 or the control knob 124 rotates the other in thedirection permitted by the clutch device 160.

FIG. 7 shows the attachment pin 116 positioned within the pin bore 120of the base 108 and engaged with the pinion 156 of the drive shaft 150.As seen, the resilient member 166 can bias the drive shaft 150 into theposition wherein the pinion 156 engages the notches 118 of theattachment pin 116. In the position shown in FIG. 7, distal or downwardmovement of the attachment pin 116 through the pin bore 120 rotates thepinion 156 and the drive shaft 150 in the direction permitted by theclutch device 160, which, in turn, spins the projections 126, 128 of thecontrol knob 124 extending a distance D from the side of the base 108.

A user can see the projections 126, 128 spinning, providing a clearindictor to the user that the attachment pin 116 is being correctlypushed into the lock mechanism 122. The distance D may be selected suchthat the projections 126, 128 can spin without interference from thebase 108. The longitudinal axis L of the lock mechanism 122 may bearranged obliquely relative to the base 108, and/or the projections 126,128 may be arranged to extend obliquely by the distance D relative tothe base 108.

When the projections 126, 128 of the control knob 124 stop spinning, theuser can easily grasp the large gripping area provided by theprojections 126, 128 to turn the control knob 124 in the same directionas it was spinning. If the user cannot turn the control knob 124, theattachment pin 116 is fully and safely engaged with the lock mechanism122. If the user can turn the control knob 124, the manual rotation ofthe control knob 124 by the user is configured to draw the attachmentpin 116 into the lock mechanism 122 until it is fully and safely engagedby the engagement between the pinion 156 of the drive shaft 150 and theteeth or pegs 118 of the attachment pin 116.

When it is desired to remove the attachment pin 116 from the base 108,the control knob 124 can be configured so a user can push the controlknob 124 inwardly to disengage the lock mechanism 122 from theattachment pin 116. The outer surface of the central portion 130 of thecontrol knob 124 can provide a large and substantially flat surface.This advantageously makes it easier and more comfortable to push thecontrol knob 124 inwardly. The attachment pin 116 may be freelywithdrawn from the base 108 upon disengagement of the lock mechanism 122from the attachment pin 116 as the pinion 156 is translated deeperwithin the transverse bore 168.

The control knob 124 of the present disclosure in combination with thelock mechanism 122 thus makes donning and doffing of the socket 102easier and minimizes incorrect locking of the prosthetic socket system100.

The lock mechanism 122 is nearly entirely located in the base 108 of thesocket 102 eliminating the use of a conventional lock body which istypically located below the distal surface of the socket. Thisadvantageously reduces the weight, complexity, and cost of theprosthetic socket system 100.

Referring to both FIGS. 7 and 8, the base 108 connects the longitudinalsupports 110 (shown in FIG. 1) and is configured to provide support fora distal end of the residual limb. The base 108 comprises a body 170having a main portion 172 and a connecting portion 174 having first andsecond connection portions 174 a, 174 b extending outwardly and upwardlyfrom a lower region of the main portion 172. The base 108 can be formedof any suitable material such as plastic, metal, carbon fiber, orcombinations thereof.

The upper surface of the connecting portions 174 a, 174 b defines a seat178 arranged to generally correspond to the configuration of a distalend portion of the longitudinal support 110. In an embodiment, the seat178 defines a curvature generally corresponding to a curvature to anouter surface of the distal end portion of the longitudinal support 110such that as the distal end portion is moved up and down on the seat178, the angle of the longitudinal support 110 varies. The curvatureand/or length of the seat 178 can define a range of angular adjustmentsfor the longitudinal support 110. Each connecting portion 174 a, 174 bdefines at least one elongated opening 176 arranged to receive fastenersfor attaching the longitudinal supports 110 to the base 108.

The base 108 further includes a pair of wall segments 180 separated fromone another by the main portion 172 and extending between and connectingthe connecting portions 174 a, 174 b. The wall segments 180 both providereinforcement and help resist movement of the connecting portions 174relative to one another. The walls 180 further help protect the distalend portion of the longitudinal supports 110 and the main portion 172and restrict side to side movement of the distal end portion of thelongitudinal supports 110 on the base 108. Open areas 182 are formed inthe base 108 between the main portion 172 and the connecting portions174 for accommodating the distal end portions of the longitudinalsupports 110. In addition, these open areas 182 beneficially reduce theoverall weight and cost of the base 108. The open areas 182 are shownextending partially through the thickness of the base 108 but in otherembodiments can extend entirely therethrough.

The main portion 172 extends between the wall segments 180 and defines athickness between its upper and lower surfaces that is sized toaccommodate the lock mechanism 122. The main portion 172 includes thepin bore 120 formed therethrough, and the transverse bore 168 extendingtherein and intersecting at least a portion of the pin bore 120. Inembodiments, the transverse bore 168 extends generally orthogonalthrough the main portion 172 to the pin bore 120.

An annular flange 184 surrounds the pin bore 120 and extends axiallyupward from a top of the pin bore 120 as best shown in FIG. 8. Theannular flange 184 can include a conical inner surface configured tofunnel or guide the attachment pin 116 into the pin bore 120. Theannular flange 184 can also be sized to fit within a correspondingannular flange 186 surrounding the opening in the umbrella 114 andextending downward from a bottom of the umbrella 114, as seen in FIG. 9.For instance, the annular flange 184 on the main portion 172 can form amale part configured to closely fit within the annular flange 186 of theumbrella 114 forming a female part when the attachment pin 116 is fullyinserted in the pin bore 120.

This arrangement advantageously helps maintain the desired alignmentbetween the base 108 of the socket 102 and the prosthetic liner 104. Inaddition, it makes donning of the socket 102 easier by helping to alignthe attachment pin 116 with the pin bore 120. This also helps forgivepoor alignment of the prosthetic liner 104 within the socket 102. Itwill be appreciated that in other embodiments, the annular flange 186 ofthe umbrella 114 can fit within the annular flange 184 of the mainportion 172. In yet other embodiments, the umbrella 114 and main portion172 can include one or more different alignment features.

Referring to FIG. 8, the main portion 172 is shown having a trapezoidalcross-section, providing a larger base toward the bottom of the base 108for accommodating the lock mechanism 122 and supporting the distal endof the residual limb. In other embodiments, the main portion 172 canhave a rectangular cross section, an elliptical cross section, a squarecross section, an irregular cross-sectional shape, or any other suitablecross-sectional shape.

In an alternative embodiment shown in greater detail in FIGS. 10 and 11,a control knob 424 may be provided with a lock mechanism 422 similar tothe foregoing embodiments. The lock mechanism 422 may be configured tocooperate with the control knob 424 such that, rather than beingconfigured to be pushed or pressed inward by a user in order todisengage or engage the lock mechanism and the pin attachment, thecontrol knob 424 is pulled outwardly by a user in order to engage ordisengage the lock mechanism 424 from a pin attachment 116.

The control knob 424, as shown, may be provided with a central portion430 flanked on opposed sides by first and second projections 426, 428.The first and second projections 426, 428 may be curved inwardly towardthe base 408 of the lock assembly, defining a curvature and maintaininga minimized profile. The first and second projections 426, 428 can beconfigured such that a user can intuitively grasp the first and/orsecond projections 426, 428 for straightforwardly manipulating thecontrol knob 424, and such that spinning of the control knob 424 as theattachment pin 116 is progressively engaged with the bore 420 is notimpeded.

To this end, a distance D41 may be defined between a nearer projectionof the first and second projections 426, 428, ensuring that a user cangrasp the control knob 424 and that the control knob 424 can rotatefreely about a rotation axis 431. The distance D41 and the configurationof the control knob 424 may be chosen so that accidental release of theattachment, such as by the control knob 424 catching on outside objectslike clothing, furniture, or otherwise, is minimized withoutcompromising convenience and intuitiveness of use. A neck portion 436 ofthe control knob 424 may further distance the control knob 424 from asurface of the base 408, allowing for manipulation of the control knob424 by a user.

The first and second projections 426, 428 may have any suitableconfiguration and material properties; in embodiments, the projections426, 428 may be substantially rigid, such that the projections 426, 428cannot be readily bent outward when a user grasps the control knob 424.In other embodiments, the projections 426, 428 may be at least partiallyflexible for ease and comfort of manipulating the control knob 424.

The lock mechanism 422, similar to previous embodiments, may define orcomprise a pinion 456 that is arranged to engage with individual teeth118 of the attachment pin 116, with a transverse bore 458 in which thelock mechanism 422 operates situated such that an appropriate degree ofcontact between the attachment pin 116 and the lock mechanism 422 isfacilitated. The lock mechanism 422 may comprise a draft shaft 450operatively connecting the pinion 456 to the control knob 424 along alength of the transverse bore 458. As in the previously describedembodiment, a sleeve assembly 452 may be provided along the draft shaft450.

The drive shaft 450 and the sleeve assembly 452 may cooperate with aone-way clutch device 460 to ensure that insertion of the attachment pin116 is permitted to rotate the lock mechanism 422, while retaining theattachment pin 116 and accordingly the prosthetic liner 102 in place andpreventing unwanted detachment of the prosthetic system components. Theresilient element 466 may be arranged to bias the draft shift 450 intoengagement with the attachment pin 116. Whereas the lock mechanism 122of the embodiment shown in FIGS. 6 and 7 is configured such thatdepression of the control knob 124 urges the draft shaft 150 inwardly,thereby disengaging the pinion 156 from the notches 118 of theattachment pin 116, the lock mechanism 422 of the embodiment of FIGS. 10and 11 is configured such that pulling on the control knob 424 urges theshaft 450 outwardly to disengage the pinion 456 from the notches 118 ofthe attachment pin 116.

As the control knob 424 is manipulated by a user, such as to pull thecontrol knob 424 substantially outwardly away from the base 408, theresilient element 466 may be compressed and the pinion 456 may disengagefrom the attachment pin 116, allowing for quick release of theattachment pin, for example during doffing. When the user ceases frompulling on the control knob 424, the bias provided by the resilientelement 466 returns the lock mechanism 422 to the engaged configuration.In this manner, the donning and doffing of the prosthetic system, andthe attachment between components of the prosthetic system, may bedeliberate, controlled, and intuitive, while avoiding catastrophicfailure of the components.

The base 408 may define a main portion 472 through a portion of thethickness of which the bore 420 may be defined and through which theattachment pin 116 may extend. The main portion 472 may be flanked byconnecting portions 474, elongate openings 476, wall segments 480, andother features as previously described. The main portion 472 may definea shape or profile 473 that is asymmetric and serves to, among otherfunctions, reduce a bulk, weight, and cost of the socket 102. Thedepicted embodiment is merely exemplary, and the profile 473 may extendin any configuration, location, number, or extent. As describedpreviously, the base 408 may also define an annular flange 484 proximateand/or surrounding the bore 420, the annular flange 484 sized andconfigured to guide the attachment pin 116 into the bore 420, furtherfacilitating and easing the process of properly attaching the componentsof a prosthetic attachment system.

By providing a control knob operating with a lock mechanismcorresponding to a prosthetic attachment system according to theembodiments of the disclosure, the problem of prosthetic systems beingdifficult or counter-intuitive to attach, particularly between aprosthetic liner and a prosthetic socket, is addressed. The arrangementand function of the control knob and lock mechanism of the disclosureadvantageously provides an intuitive indicator of the attachment betweenan attachment pin and a pin bore, and further provides an intuitive andconvenient manner of adjusting or releasing the degree of attachmentbetween an attachment pin and a pin bore.

Although this disclosure describes certain exemplary embodiments andexamples of a prosthetic socket system including a lock assembly, itnevertheless will be understood by those skilled in the art that thepresent disclosure extends beyond the specifically disclosed prostheticsocket and prosthetic attachment system embodiments to other alternativeembodiments and/or users of the disclosure and obvious modifications andequivalents thereof. It is intended that the scope of the presentdisclosure should not be limited by the particular disclosed embodimentsdescribed above, and may be extended to prosthetic devices and supports,and other applications that may employ the features described herein.

The invention claimed is:
 1. A lock assembly for connecting a distal endof a prosthetic liner to a distal end of a prosthetic socket, the lockassembly comprising: a base arranged to be supported by the distal endof the prosthetic socket, and defining a bore; an attachment pinarranged to be carried by the prosthetic liner and insertable throughthe bore; a lock mechanism arranged to be carried by the base androtatable about a rotation axis, the lock mechanism including a controlknob extending outwardly from a side of the base and having at least oneelongate projection extending in a direction transverse relative to therotation axis; wherein the attachment pin is arranged to interact withthe lock mechanism as the attachment pin moves distally through thebore, and to cause the control knob to spin the at least one elongateprojection about the rotation axis; wherein the at least one elongateprojection extends obliquely a predetermined distance from and relativeto a side of the base without interference from the base; wherein the atleast one elongate projection extends radially from a central portionincluding the rotation axis; wherein an outer surface of the controlknob includes at least one textured region configured to provide tactilefeedback to a user.
 2. The lock assembly of claim 1, wherein the lockmechanism is arranged so that the at least one projection of the controlknob stops spinning about the rotation axis when the attachment pin isfully inserted in and/or through the bore to a predetermined extent. 3.The lock assembly of claim 1, wherein the lock mechanism comprises anengaging member operably communicating with the bore and adapted toselectively engage at least one notch among notches defined by theattachment pin as the attachment pin is inserted within and through thebore.
 4. The lock assembly of claim 3, wherein the engaging member is apinion connected to and extending along the rotatable axis of thecontrol knob.
 5. A lock assembly for connecting a distal end of aprosthetic liner to a distal end of a prosthetic socket, the lockassembly comprising: a base arranged to be supported by the distal endof the prosthetic socket, and defining a bore; an attachment pinarranged to be carried by the prosthetic liner and insertable throughthe bore, the attachment pin defining notches along a longitudinallength thereof; a lock mechanism arranged to be carried by the base androtatable about a rotation axis, the lock mechanism including a controlknob extending outwardly from a side of the base, the control knobhaving at least one elongate projection extending in a directiontransverse relative to the rotation axis, the lock mechanism furthercomprising a pinion operably communicating with the bore and adapted toselectively engage at least one notch among the notches of theattachment pin as the attachment pin is inserted within and through thebore; wherein as the attachment pin is inserted through and within thebore, the control knob is arranged to spin the at least one elongateprojection about the rotation axis; wherein the at least one elongateprojection extends obliquely a predetermined distance from and relativeto a side of the base without interference from the base; wherein the atleast one elongate projection extends radially from a central portionincluding the rotation axis; wherein an outer surface of the controlknob includes at least one textured region configured to provide tactilefeedback to a user.
 6. The lock assembly of claim 5, wherein the lockmechanism comprises a shaft carrying the pinion at a first end andconnecting a second end to the control knob, a sleeve assemblyencompassing at least a portion of the shaft, a bearing and groovearrangement configured to provide cooperative movement between thesleeve assembly and the shaft, and a clutch device arranged to receivethe sleeve assembly and to permit generally uniform rotation of theshaft, the sleeve assembly, the control knob, and the clutch deviceextending commonly along the rotatable axis.
 7. The lock assembly ofclaim 6, wherein the shaft further includes a threaded portion locatedat the second end thereof, and a central portion interposed between thepinion and the threaded portion, the pinion is configured and arrangedto engage the attachment pin such that teeth of the pinion mesh withnotches of the attachment pin.
 8. The lock assembly of claim 7, whereinthe shaft defines at least one groove longitudinally extending along thecentral portion of the shaft, the at least one groove having a depthwith contours to accommodate at least a portion of at least one ballbearing, the sleeve assembly defines along an interior surface thereofat least one groove located at or near a first end portion intended tobe near or adjacent to the pinion, the sleeve assembly is positioned onthe shaft such that the grooves of the sleeve assembly are aligned withthe at least one groove of the shaft, a groove of the shaft and acorresponding groove of the sleeve assembly defining a pair of mutuallyopposed grooves, wherein the lock mechanism is configured such that theat least one ball bearing is seated in each pair of mutually opposedgrooves of the shaft and the sleeve assembly, respectively.
 9. The lockassembly of claim 8, wherein the at least one groove is arranged topermit the shaft to move within the sleeve assembly a predetermineddistance until the pinion completely disengages from the notches of theattachment pin so as to permit the attachment pin to be freely removedfrom the lock assembly.
 10. The lock assembly of claim 6, furthercomprising a coupler including a first end arranged to couple with thedrive shaft, and a second end arranged to couple with the control knob,and a radially extending flange defined between the first and secondends.
 11. The lock assembly of claim 10, further comprising a resilientmember configured to engage between the radially extending flange and aseat flange of the clutch device, such that depression of the controlknob urges travel of the drive shaft along a longitudinal axis of thelock mechanism, and rotation of the control knob rotates a directionabout the rotation axis permitted by the clutch device.
 12. The lockassembly of claim 11, wherein the resilient member is arranged to biasthe drive shaft into a position whereat the pinion engages the notchesof the attachment pin.
 13. The lock assembly of claim 5, wherein thebase comprises a body having a main portion and first and secondconnection portions extending outwardly and upwardly from a lower regionof the main portion, the base forms open areas between the main portionand the first and second connection portions.
 14. The lock assembly ofclaim 13, wherein the base further includes a pair of wall segmentsseparated from one another by the main portion and extending between andconnecting the first and second connecting portions.
 15. The lockassembly of claim 5, wherein the base defines an annular flangesurrounding the bore and extending axially upward from a top of thebore, the annular flange forming a conical inner surface configured toguide the attachment pin into the bore.